EP0089756A1 - Filtres de particules utilisés sur des moteurs diesel - Google Patents

Filtres de particules utilisés sur des moteurs diesel Download PDF

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Publication number
EP0089756A1
EP0089756A1 EP83301052A EP83301052A EP0089756A1 EP 0089756 A1 EP0089756 A1 EP 0089756A1 EP 83301052 A EP83301052 A EP 83301052A EP 83301052 A EP83301052 A EP 83301052A EP 0089756 A1 EP0089756 A1 EP 0089756A1
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Prior art keywords
cells
filter
face
open
inlet
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Application number
EP83301052A
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German (de)
English (en)
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EP0089756B1 (fr
Inventor
Rodney Irving Frost
Max Romney Montierth
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Corning Glass Works
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Corning Glass Works
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2072—Other inorganic materials, e.g. ceramics the material being particulate or granular
    • B01D39/2075—Other inorganic materials, e.g. ceramics the material being particulate or granular sintered or bonded by inorganic agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
    • B01D46/24—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies
    • B01D46/2403—Particle separators, e.g. dust precipitators, using rigid hollow filter bodies characterised by the physical shape or structure of the filtering element
    • B01D46/2418—Honeycomb filters
    • B01D46/2422—Mounting of the body within a housing
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B33/00—Clay-wares
    • C04B33/02—Preparing or treating the raw materials individually or as batches
    • C04B33/13—Compounding ingredients
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
    • C04B38/0006—Honeycomb structures
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/0211—Arrangements for mounting filtering elements in housing, e.g. with means for compensating thermal expansion or vibration
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N3/00—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust
    • F01N3/02—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust
    • F01N3/021—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters
    • F01N3/022—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous
    • F01N3/0222—Exhaust or silencing apparatus having means for purifying, rendering innocuous, or otherwise treating exhaust for cooling, or for removing solid constituents of, exhaust by means of filters characterised by specially adapted filtering structure, e.g. honeycomb, mesh or fibrous the structure being monolithic, e.g. honeycombs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2275/00—Filter media structures for filters specially adapted for separating dispersed particles from gases or vapours
    • B01D2275/30—Porosity of filtering material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2330/00—Structure of catalyst support or particle filter
    • F01N2330/06—Ceramic, e.g. monoliths
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
    • F01N—GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR MACHINES OR ENGINES IN GENERAL; GAS-FLOW SILENCERS OR EXHAUST APPARATUS FOR INTERNAL COMBUSTION ENGINES
    • F01N2350/00—Arrangements for fitting catalyst support or particle filter element in the housing
    • F01N2350/02—Fitting ceramic monoliths in a metallic housing
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02B—INTERNAL-COMBUSTION PISTON ENGINES; COMBUSTION ENGINES IN GENERAL
    • F02B3/00—Engines characterised by air compression and subsequent fuel addition
    • F02B3/06—Engines characterised by air compression and subsequent fuel addition with compression ignition
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
    • Y02T10/00—Road transport of goods or passengers
    • Y02T10/10—Internal combustion engine [ICE] based vehicles
    • Y02T10/12—Improving ICE efficiencies
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S55/00—Gas separation
    • Y10S55/30—Exhaust treatment

Definitions

  • This invention relates to diesel engine exhaust particulate filters of honeycomb structure, hereinafter referred to as "DPF's", and, in particular, to improved DPF's for smaller displacement diesel engines.
  • each DPF has a multiplicity of interconnected thin porous walls which define at least one inlet surface and one outlet surface on the filter and a multiplicity of hollow passages or cells extending through the filter from an inlet surface or an outlet surface or both.
  • Inlet cells are formed open at at least one inlet surface to admit contaminated fluid into the filter. The inlet cells are closed where they adjoin any outlet surface of the filter.
  • Outlet cells are formed open at an outlet surface to discharge fluid which has passed through the filter.
  • the outlet cells are similarly closed where they adjoin any inlet surface.
  • the interconnected thin walls are provided with an internal interconnected open porosity which allows the fluid to pass from the inlet to the outlet cells while restraining a desired portion of the solid particulates in the fluid from passing therethrough.
  • the pa ' rticualtes are trapped in or collected on the surface of the thin walls defining the inlet cells.
  • DPF's are typically installed in a housing which is inserted like a muffler or catalytic converter into the exhaust system of a diesel engine equipped vehicle.
  • the 1980 Oldsmobile 350 CID (.9 litre V-8 engine used for comparatively testing filter compositions and configurations generated particulates at an average rate, per 4 cylinder bank of the engine, of between about 0.17 and 0.24 g/mi. (0.11 and 0.15 g/km) under steady state moderate speed operation (approximately 30 mph constant or 48 km/hr).
  • the same engine would produce particulates at average rates of about 0.5 and 0.6 g/mi (0.31 and 0.37 g/km) during a normal driving cycle.
  • the term "normal driving cycle" is used in the same manner as it is used in E.P.A.
  • Recent certification testing of diesel engines-for use in 1982 light duty vehicle engines, including larger V-6 and V-8 engines to be offered will generate particulates at average rates of about 0.45 g/mi. (0.28 g/km) or less over normal driving cycles and a significant majority of those engines will generate particulates at average rates of about 0.35 g/mi (0.22 g/km) or less of the normal driving cycle.
  • DPF's or other apparatus will not be required in the U.S.A. in most diesel engine equipped vehicles for 1982 but apparently will be required in virtually all vehicles equipped with existing types of diesel engines by 1985 to meet the Federal diesel particulate emission restrictions.
  • filter efficiency that is, the amount of suspended particulates which are removed from the fluid as it is passed through the filter (hereinafter expressed as a percentage of the weight of all particulates in the fluid prior to its passage through the filter).
  • filter efficiency is the amount of suspended particulates which are removed from the fluid as it is passed through the filter (hereinafter expressed as a percentage of the weight of all particulates in the fluid prior to its passage through the filter).
  • pressure drop across the filter that is the difference between the fluid upstream and downstream from the filter caused by the presence of the filter and particulates therein. As pressure drop increases so does the engine exhaust back pressure.
  • Useful operating time is the cumulative time of service of a DPF until its pressure drop and engine exhaust back pressure become sufficiently great to necessitate the regeneration or replacement of the filter.
  • compact structure the smallest space-saving volume and configuration of the filter for obtaining the best combination of filter efficiency, back pressure characteristics and useful operating time.
  • Other desirable features include thermal shock resistance, mechanical strength and non-deleterious reaction with the exhaust gases
  • the U.S. Patent 4,276,071 describes the characteristics of a DPF having a single inlet end face and a single outlet end face on opposing surfaces.of the filter and a multiplicity of cells extending through the filter in a mutually parallel fashion between the inlet and outlet end faces.
  • This type of filter is hereinafter referred to as a "unidirectional flow-type"DPF.
  • the thin walls forming the cells of the filter are described as having an open porosity with a 10% internal open volume formed by pore spaces having mean sizes ranging between about 2 to 15 microns.
  • the patent further describes using a pair of such filters with an 8 cylinder, V-type automotive diesel engine, each filter being connected with one of the engine's two banks of four cylinders.
  • the aforesaid European Patent Specification 0043694A describes several ceramic batch mixtures for fabricating DPF's with porous thin walls having internal open volumes ranging between about 35% and 66% formed by pores having mean diameters ranging between about 4 and 35 microns, and refers to a field of DPF thin wall open porosities having open pore volumes and mean pore sizes ranging between about 35 to 90% and about 1 to 20 microns, respectively.
  • filters formed with thin walls having open porosities lying within the field to have acceptable pressure drop characteristics and filtration efficiencies of about 75% or more in desired filter configurations, levels which would be needed to ensure meeting the 1985 Federal particulate emission standards with the largest displacement diesel engines being offered in the 1980-1981 period, and to provide extended useful operating life when compared with the performance of a comparably dimensioned D PF having the thin wall open porosity disclosed in the U.S. Patent 4,276,071.
  • a solid particulate filter for use in an exhaust system of a light duty vehicle diesel engine emitting particulates at a rate of less than about 0.45 g/mile (0.28 g/km) in a normal driving cyle and comprising conduit means for carrying engine exhaust gases away from the engine for disposal into the atmosphere, the solid particulate filter being positioned,. in use, within the conduit means across the exhaust gas path, the filter comprising:
  • the thin walls are formed no more than about 0.76 mm thick and, more preferably about 0.30 mm. thick, for improving thermal shock performance while optimizing compact filter size, pressure drop and efficiency.
  • Preferably all thin walls are of the same substantially uniform thickness.
  • the filter is a unidirectional flow-type having one inlet end face and one outlet end face on opposing outer surfaces of the filter, in which the inlet and outlet cells extend in a substantially longitudinally and mutually parallel fashion through the filter between the two end faces.
  • the transverse cross-sectional density of the cells is preferably at least about 4 cells/cm and, more preferably, between about 15.5 and 31 cells/cm 2 for maximizing filter surface area within a compact structure.
  • Fig. 1 depicts diagrammatically the chassis 10 of a light duty vehicle 8 mounting a small displacement diesel engine 12.
  • the engine 12 typically has four cylinders as depicted, although as many as eight cylinders or fewer than- four cylinders may be provided.
  • the engine 12 produces particulates at an average rate no greater than about 0.45 g/mile (0.28 g/km) in a normal driving cycle as that term is used in EPA regulations, Title 40, Consolidated Federal Regulations July 1981, Rev., incorporated by reference herein, particularly as used in Sections 86.082-8,86.082-9 and 86.101 et seq.
  • the engine may be one of current (i.e. 1981) design having a smaller cylindrical displacement.. (i.e.
  • An exhaust manifold 14 is mounted to the engine 12 to collect the exhaust gases generated by the engine cylinders and is in turn connected to the remainder of the vehicle's exhaust system comprising pipes 16,17 and 18, a diesel particulate filter housing or can 20 and a muffler 22. It is envisaged that where two banks of cylinders are provided in the engine 12, as in a V-type engine, a second manifold (not depicted) and exhaust pipe 24 (indicated in phantom) will be provided to carry exhaust gases generated by the second row of cylinders to the DPF can 20.
  • the exhaust pipes 24 and 16 form a "Y" junction where they meet.
  • a can 20 with filter may be installed in each pipe 16 and 24 to filter the exhaust from a pair of engine cylinder banks.
  • the can 20 is formed and installed in a conventional fashion as is depicted and described in the aforesaid European Patent Specification 0043694A.
  • Fig. 2 reveals the construction of the can 20 and the mounting of a unidirectional flow-type diesel particulate filter 30 contained therein.
  • the can 20 is similar to a conventional type of can employed for mounting catalytic converter honeycomb substrates in exhaust systems as is described, for example, in U.S. Patent 3,441,381.
  • the can 20 comprises two substantially identical filter-holding shells 26 and 26' having mating flanges 27 and 27', respectively, which are mechanically fastened together (e.g. by nuts and bolts not shown) to keep the can 20 assembled during use and to allow disassembly for regeneration or replacement of the filter 30.
  • the one shell 26 is connected to the upstream exhaust pipe 16 (in phantom) and the remaining shell 26' is connected to the downstream exhaust pipe 17 (in phantom), both by conventional means such as welding, brazing or clamps (not depicted).
  • Internal annular mounting members 28 and 28' of L-shaped cross-sections are respectively fastened to the shells 26 and 26' so as to abut against faces 34 and 36 of the filter 30 (preferably with customary sealing material therebetween) holding it in proper fixed axial position within the can 20.
  • the wrapping or mat 29 may include a layer of insulating material such as glass or mineral wool mat 29'.
  • the filter 30 is also depicted in a perspective view in Fig. 3 with its outer wall 42 partially broken away.
  • the filter 30 comprises a multiplicity of interconnected thin walls 32 forming a matrix defining an inlet end face 34 in communication with the exhaust gases coming from the engine 12 upstream from the filter 30, represented in Fig. 2 by lined arrows 48, and an outlet end face 36 on the opposite outer surface of the filter 30 in communication with the exhaust gases downstream of the filter 30 flowing to disposal into the atmosphere, represented again in Fig.
  • the filter 30 is also provided with a smooth outer wall or skin 42 interconnected with and extending continuously around the matrix of thin walls 32 and between the end faces 34 and 36.
  • a group of inlet cells 38 are open at the inlet end face 34 and closed where they appear at the outlet end face 36.
  • a group of outlet cells 40 are open at the outlet end face 36 and closed near the inlet end face 34.
  • Each of the cells is closed at one and desirably only one of the two end faces 36 and 34 to form an inlet or outlet cell 38 or 40, respectively.
  • Cells may be closed at both end faces 34 and 36, although this will reduce the filtration capacity and thus the useful filter operating life. It is undesirable to leave any of the cells open along their entire length as this would allow the exhaust gas contaminants to pass unrestrictedly through the filter 30.
  • the plugs 46 at the inlet end face 34 of the outlet cells 40 have been shaded for clarity.
  • the cells 38 and 40 are plugged in a checkerboard fashion with each inlet cell 38 adjoining and sharing thin walls 32 in common with only outlet cells 40 and vice versa. It will also be appreciated that the pattern of plugs 46 of the outlet cells 40 visible on the inlet end face 34 of the filter 30 in Fig. 3 is thus reversed at the outlet end face 36 (not depicted) with the plugs 44 of the inlet cells 38.
  • Contaminated fluid 48 is brought from the manifold 14 through the pipe 16 (and pipe 24, if provided) to the can 20 and inlet end face 34 of the filter 30 where it enters the inlet cells 38. Because the inlet cells 38 are closed near the outlet end face 36, the contaminated fluid within the cells 38 passes predominantly through the interconnected open porosity of the thin walls 32, in the manner indicated by the lined arrows 50, into the outlet cells 40 adjoining each inlet cell 38.
  • the now filtered fluid 52 passes from the filter body 30 through the outlet cells 40 and from the can 20 into the pipe 17 for disposal to the atmosphere through the remainder of the exhaust system.
  • the thin walls 32 also contain sufficient interconnected open porosity for the fluid to flow through the longer dimensions of the thin wall (not depicted).
  • Fig. 4 is a perspective view of a second embodiment unidirectional flow-type diesel particulate filter 60 again formed by a multiplicity of interconnected thin porous walls 62 which define an inlet end face 64 and an outlet end face 66 on opposing outer surfaces of the filter 60 and a multiplicity of hollow cells 68 and 70 extending in a substantially longitudinal and mutually parallel fashion through the filter 60 between the end faces 64 and 66.
  • a continuous outer wall or skin 72 has been provided extending around the thin walls 62 and between the end faces 64 and 66.
  • Plugs 74 close the ends of outlet cells 70 of the filter 60 near its inlet end face 64 while plugs 76 close the ends of inlet cells 68 near the outlet end face 66.
  • the filter 60 of Fig. 5 contains three times as many inlet cells 68 as outlet cells 70 so as to asymmetrically allocate the exposed surface areas of the thin wall in favour of the inlet cells as is described in European Patent Application No. 83300915.2 and U.S. Serial No. 350,994.
  • Asymmetrically allocating the thin wall surface areas in favour of inlet cells provides a higher initial filter pressure drop but a reduced back pressure increase rate due to particulate build up, generally yielding greater particulate capacity and useful operating life for filters of otherwise essentially similar makeup. Operation of the filter 60, as well as fluid flow through the longer dimensions of the thin walls of both filters 30 and 60 are described in the above European Patent Application No.. 83300915.2 and U.S. Serial . No. 350,994.
  • the matrices of thin walls 32 and 62 may be formed from any suitable material providing the desired interconnected open porosity. These materials inlcude powdered metals, glasses, ceramics (generally crystalline), resins or organic polymers, and papers or textile fabrics (with or without fillers), or combinations thereof including, for example, glass-ceramic mixtures and cermets. It is preferred to fabricate the thin walls 32 and 62 from plastically formable and sinterable finely divided particulates and/or short length fibres of substances that yield a porous sintered material after being fired to effect the sintering thereof, especially powdered metals, glasses, and ceramic based materials including, in addition to conventional ceramics, glass-ceramics, cermets and other ceramic based mixtures.
  • any suitable fugitive or combustible (burn-out) additive can be dispersed within the formable and sinterable mixture so as to provide substantially uniformly distributed and randomly interconnected open porosity in the sintered thin walls 32 and 62 after firing.
  • the requisite open porosity can be designed into the thin walls 32 and 62 by raw material selection as described in U.S. Patent 3,950,175.
  • matrices of interconnected thin walls 32, 62 including those of the four batch mixture compositions of TABLE I, are preferably formed monolithically with a skin 42, 72 by extrusion in the manner disclosed in U.S. Patents 3,790,654, 3,919,384, 4,008,033 and 4,364,888.
  • the TABLE I batch mixture substrates are dried and fired generally in accordance with the following firing schedule:
  • Thin walls 32, 62 can be formed from the batch mixtures of TABLE I in thicknesses of about 0.002 inches (about 0.05 mm) or more although thicknesses of about 0.030 inches (about 0.76 mm) or less are desired and of about 0.012 inches (about 0.30 mm) are preferred for maximizing structural integrity while minimizing susceptibility of the resultant filter to thermal shock which is dependent, in part, upon thin wall thickness.
  • Cellular transverse cross-sectional densities of between about 25 and 400 cells/in.2 (about 3.9 and 62 cell/cm 2 , respectively), are typically useful.
  • a cell density of about 200 cells/in. 2 (about 31 cells/cm 2 ) is preferred for performance (i.e. to minimize filter size without unduly restricting cell channel size to provide about 60% efficiency and low pressure drop) but densities closer to 100 cells/in. 2 (about 15.5 cells/cm 2 ) are preferred for ease of manufacture with present technologies.
  • Fig. 5 is a graphical representation of DPF thin wall open porosity represented by a pair of open pore volume . (ordinate) and mean pore size diameter (abscissa) values.
  • the open porosities of the batch mixtures 1 through 4 of TABLE II are indicated by the points 1 through 4, respectively.
  • Open porosities (pairs of open pore volume and mean pore diameter values) lying within the area encompassed by the lines connecthg the points A-B-C-D provide DPF thin walls having the desired efficiencies (less than about 70%) at about optimum thin wall thickness (about 0.012 in.).
  • Area A-B-C-D has the following coordinate values:
  • the line connecting the points A and D represents the suggested upper limits of open porosity to provide adequate filter strength at the desired thin wall thicknesses; the line connected the points B and C represents the minimum suggested open pore volume (30%) to provide acceptable pressure drop in the resulting filter; the line connecting the points C and D represents the practical upper limit of mean pore size (55 microns) based on present manufacturing technologies, particularly talc manufacture; and the line connecting the points A and B represents the combination of open pore volume and mean pore diameter providing efficiencies of about 70% or less in the desired thin wall thicknesses.
  • the ends of the cells 38, 40, 68 and 70 may be closed with any material and/or in any manner compatible with the material of the thin walls 32 and 62 under the envisaged service conditions of the filter 30 and 60. This includes non-deleterious reaction with the thin wall material and/or diesel exhaust gas, good adhesion to the thin wall material, suitable durability to gas flow.at the experienced low flow rates, similar coefficients of thermal expansion.
  • plugs 44, 46, 74 and 76 are formed by charging a flowable or formable plugging material into selected cell ends and then curing, drying or firing the structure to transform the formable/flowable material into a solid closure which adheres mechanically and/or chemically to the thin walls 32 or 62 and completely covers or fills the cell ends.
  • the plugs 44, 46, 74 and 76 or other closure means may be either porous or non-porous, although in the former case, the open porosity (i.e., pore volume and mean pore size) should be sufficient to prevent the passage of at least undesirable amounts of solid particulates through or around the plugs and hence through the filter 30 or 60.
  • Plugs for the cordierite substrates formed from the TABLE.I batch mixtures are preferably formed in appropriate cells ends with a foaming ceramic cement which is described generally in European Patent Specification 0043694A.
  • the cement expands and reacts to a primarily cordierite crystal phase when fired.
  • a particular pomposition of that cement described in that specification is preferred for use in DPF's and other automotive exhaust applications.
  • a punched tape or elastic mask described in European Patent Specification 0070203A and 0070671A respectively, are used in charging and foaming cement into the cell ends.
  • the transverse cross-sectional geometry of the cells 38, 40, 68 and 70 may be squares of substantially uniform size as is depicted in the two described embodiments, other geometries including those which are disclosed in the U.S. Patent 4,276,071 and the aforesaid European Patent Specification 0043694A and/or different cell sizes may also be used. If other geometries and/or sizes are used, the thin walls 32 and 62 should be designed to intersect so as to form included angles that are preferably not less than about 60° to avoid non-uniform accumulation of particles of smaller angle corners and to assist in the proper plugging of the cell ends adjoining the end faces 34, 36, 64 and 66 as is described and claimed in the aforesaid European Patent.
  • filters can be formed having a plurality of transverse sectors (e.g., annular or wedge shape) distinguished by the size or shape of their cells, or both. It is further envisaged that patterns of different cellular transverse geometric shapes can be repeated across the end faces of the filter or across the transverse sectors thereof.
  • a cross-flow type of filter such as is described in the aforesaid U.S. Patent 4,276,071 may be fabricated with thin walls having an open porosity lying within the area A-B-C-D of Fig. 6 for use with light duty vehicle diesel engines operating at particulate emission rates of about 0.45 g/mi (0.28 g/km) or less.
  • Such filters typically have one or two inlet end faces and one or two outlet end faces and a group of substantially mutually parallel inlet cells extending through the filter from (or between) the inlet end face(s) and a group of substantially mutually parallel outlet cells extending through the filter from (or between) the outlet end face(s).
  • the inlet cells are each open at at least one inlet end face and are closed proximal to each outlet end face.
  • the outlet cells are correspondingly each open at at least one outlet end face and are closed proximal to each inlet end face.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • Geology (AREA)
  • Physics & Mathematics (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Geometry (AREA)
  • Dispersion Chemistry (AREA)
  • Processes For Solid Components From Exhaust (AREA)
  • Filtering Of Dispersed Particles In Gases (AREA)
  • Filtering Materials (AREA)
EP83301052A 1982-03-01 1983-02-28 Filtres de particules utilisés sur des moteurs diesel Expired EP0089756B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US06/353,803 US4415344A (en) 1982-03-01 1982-03-01 Diesel particulate filters for use with smaller diesel engines
US353803 1982-03-01

Publications (2)

Publication Number Publication Date
EP0089756A1 true EP0089756A1 (fr) 1983-09-28
EP0089756B1 EP0089756B1 (fr) 1987-05-06

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EP83301052A Expired EP0089756B1 (fr) 1982-03-01 1983-02-28 Filtres de particules utilisés sur des moteurs diesel

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US (1) US4415344A (fr)
EP (1) EP0089756B1 (fr)
JP (1) JPS58185919A (fr)
CA (1) CA1187422A (fr)
DE (1) DE3371289D1 (fr)

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EP0205755A1 (fr) * 1985-03-08 1986-12-30 Matsushita Electric Industrial Co., Ltd. Filtre pour gaz d'échappement pour des moteurs Diesel
EP0336883A1 (fr) * 1988-04-08 1989-10-11 Per Stobbe Méthode pour filtrer des particules d'un gaz de fumée, un filtre pour gaz de fumée et un véhicule
EP0380065A1 (fr) * 1989-01-24 1990-08-01 Nissan Motor Co., Ltd. Système d'élimination de particules des gaz d'échappement d'un moteur à combustion interne
EP0507463A2 (fr) * 1991-04-05 1992-10-07 Foseco International Limited Filtres pour métaux légers
US5195319A (en) * 1988-04-08 1993-03-23 Per Stobbe Method of filtering particles from a flue gas, a flue gas filter means and a vehicle
WO1994022556A1 (fr) * 1993-04-05 1994-10-13 Per Stobbe Procede de fermeture d'un passage dans un echantillon de corps de filtrage
DE4343301A1 (de) * 1993-12-18 1995-06-22 Sut System Und Umwelttechnik G Verfahren zur Herstellung metallischer Sinterpartikelfilter
DE19522312A1 (de) * 1994-06-21 1996-01-04 Ngk Insulators Ltd Abgasfilter und Vorrichtung zur Behandlung von Abgasen
US5497620A (en) * 1988-04-08 1996-03-12 Stobbe; Per Method of filtering particles from a flue gas, a flue gas filter means and a vehicle

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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3504694A1 (de) * 1985-02-12 1986-08-14 Knecht Filterwerke Gmbh, 7000 Stuttgart Abgasfilter fuer verbrennungsmotoren
EP0205755A1 (fr) * 1985-03-08 1986-12-30 Matsushita Electric Industrial Co., Ltd. Filtre pour gaz d'échappement pour des moteurs Diesel
US5195319A (en) * 1988-04-08 1993-03-23 Per Stobbe Method of filtering particles from a flue gas, a flue gas filter means and a vehicle
EP0336883A1 (fr) * 1988-04-08 1989-10-11 Per Stobbe Méthode pour filtrer des particules d'un gaz de fumée, un filtre pour gaz de fumée et un véhicule
WO1989009648A1 (fr) * 1988-04-08 1989-10-19 Per Stobbe Procede de filtrage de particules dans un gaz de fumee, organe de filtrage de gaz de fumee et vehicule
US5497620A (en) * 1988-04-08 1996-03-12 Stobbe; Per Method of filtering particles from a flue gas, a flue gas filter means and a vehicle
EP0380065A1 (fr) * 1989-01-24 1990-08-01 Nissan Motor Co., Ltd. Système d'élimination de particules des gaz d'échappement d'un moteur à combustion interne
US5067320A (en) * 1989-01-24 1991-11-26 Nissan Motor Company, Limited Exhaust particle removing system for internal combustion engine
EP0507463A2 (fr) * 1991-04-05 1992-10-07 Foseco International Limited Filtres pour métaux légers
EP0507463A3 (en) * 1991-04-05 1993-03-17 Foseco International Limited Filters for light metals
WO1994022556A1 (fr) * 1993-04-05 1994-10-13 Per Stobbe Procede de fermeture d'un passage dans un echantillon de corps de filtrage
DE4343301A1 (de) * 1993-12-18 1995-06-22 Sut System Und Umwelttechnik G Verfahren zur Herstellung metallischer Sinterpartikelfilter
DE19522312A1 (de) * 1994-06-21 1996-01-04 Ngk Insulators Ltd Abgasfilter und Vorrichtung zur Behandlung von Abgasen
DE19522312C2 (de) * 1994-06-21 1998-07-09 Ngk Insulators Ltd Abgasfilter und Vorrichtung zur Behandlung von Abgasen

Also Published As

Publication number Publication date
EP0089756B1 (fr) 1987-05-06
JPS58185919A (ja) 1983-10-29
US4415344A (en) 1983-11-15
CA1187422A (fr) 1985-05-21
DE3371289D1 (en) 1987-06-11

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